Note: Descriptions are shown in the official language in which they were submitted.
CA 02385148 2002-05-07
COOKED BEAN PRODUCT HAVING REDUCED
SOLIDS CONTENT AND IMPROVED VISCOSITY
FIELD OF THE INVENTION
This invention relates to an improved cooked legume product having a
s reduced solids content. By incorporating a starch component, preferably a
modified food starch, during preparation of the product, particularly a
refried
bean product, the amount of bean solids is reduced and mechanical
processing of the bean product is facilitated. The incorporation of starch
also
improves the consistency and stability of the finished bean product. The
1o invention also relates to methods of preparing a stabilized cooked bean
product having reduced bean solids content, yet having an improved
viscosity, that is readily spoonable and is resistant to scorching during
reheating of the bean product for consumption.
BACKGROUND OF THE INVENTION
15 Refried beans are a popular food item common to Mexican and
Southwestern cooking styles. Traditionally, refried beans are made from
scratch using beans, water, oil, lard or other fat substances, and spices.
Such preparation is time consuming and requires some level of culinary skill
in order to achieve desired, consistent results.
2o Canned refried bean products provide a time-saving alternative to
making refried beans from scratch. The canned product requires only
reheating prior to consumption of the refried beans. As a result of the
convenience and overall simplicity of canned refried beans, use of these
products has become widespread, both by the food service trade and the
25 individual consumer.
Canned refried beans typically include water, beans, such as pinto
beans, and spices and other flavorants. The mixture is heated to fully cook
the beans and to lower the water content to provide a desired final viscosity
of
the bean product. To complete processing, the bean product is filled into
3o cans and subject to retorting.
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Due in part to the starch content of the beans, as well as the high
content of bean solids, the cooked bean product generally becomes very
viscous prior to can-filling, essentially forming a paste. The bean starch
tends
to break down during the cooking process, producing a paste-like substance.
The viscous nature of the bean paste may present concerns during
processing. As the product becomes more viscous, it becomes more difficult
to pump through process lines. Pumping difficulties may cause increased
wear on the pumps, which in turn may result in additional maintenance
requirements or more frequent replacement of the pumps. Additionally, as
the product becomes less fluid-like, metering becomes less accurate and
more difficult; in some cases, metering can become essentially impossible.
A high bean solids content also may result in the final bean product
having undesirable and variable characteristics. Upon cooling, the canned
bean product may become even more viscous and form a paste-gel product.
This paste-gel product typically is not readily spoonable and thus is
difficult to
remove from the can. Moreover, the paste-gel texture of the product may be
undesirable to consumers, as it does not resemble the texture of freshly made
refried beans.
Conventional canned refried beans also tend to be less shelf stable
2o and more variable than desired. As the refried beans are stored over time,
water separates from the bean solids and forms a layer above the bean
mass; such water separation is often observed within a few months of
manufacturing. If the refried beans are reheated on a stove top for
subsequent consumption, the ability to heat the beans evenly and to the
desired temperature may be diminished as a result, in part, of the high bean
solids content. Thus, the refried beans may easily be scorched during
reheating. Moreover, the viscosity of the final product can vary significantly
from batch to batch, often ranging from a semi-solid which is difficult to
remove from the container to a soupy consistency with a overlying water
layer.
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Decreasing the solids content of the bean product by increasing the
relative volume of water included in the product alone may not adequately
remedy these problems. Although the viscosity of the bean product will
decrease when an additional amount of water is used, the final bean product
generally may not exhibit the desired characteristics of from-scratch refried
beans (e.g., thick, chunky texture, flavorful bean taste, and the like).
Use of starch derivatives in textile, paper and prepared food
applications has been reported. For such applications, the starch granules
are often modified to change the chemical structure of the starch molecule, by
methods including oxidation, esterification, and etherification. ft is known
that
unmodified starch granules tend to swell and rupture relatively easily,
producing weak-bodied cohesive pastes or undesirable gels. Thus, it is
desirable to modify, typically through chemical treatment, a starch so that it
will withstand conditions that otherwise would result in breakdown or
gelation.
~5 Starch derivatives have been used to impart clarity, viscosity, and/or
stability
to the chosen product.
In U.S. Patent No. 3,951,947, a starch derivative for use with heat-
processed foods, such as canned pie fillings, soups, sauces, and puddings, is
described. The starch derivative is a hydroxypropylated, cross-linked, high
2o amylopectin, low amylose starch derivative that is intended to be slurried
for
use in the retort media. The starch derivative is not fully functional during
mixing and pumping but fully activates during retorting.
In U.S. Patent No. 4,973,447, a starch derivative useful in food
applications that are typically subject to freeze-thaw cycles is described.
The
2s patent teaches isolation and purification of starch, followed by
hydroxypropylation and cross-linking to provide the starch derivative. The
starch derivative is used in food products to enhance freeze-thaw stability,
as
well as for providing thickening power, clarity, and stability. Representative
applications described include products designed for freezing and products
3o subject to multiple freeze-thaw cycles, such as pie and pastry fillings,
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CA 02385148 2002-05-07
puddings, custards, yogurts, salad dressings, pasta-type products, and baked
goods.
There remains a need for compositions and processes related to
leguminous products to enhance the preparation of such products, as well as
to improve the characteristics of the final products. In particular, there is
a
need for compositions and methods that are readily processible and that will
yield a containerized leguminous product having consistent characteristics
similar to a leguminous product freshly made from scratch. Such
compositions and methods should allow a reduced amount of legume solids
to be used while maintaining the desired characteristics of the final product.
The present invention addresses these needs.
SUMMARY OF THE INVENTION
The present invention provides compositions for preparing cooked
leguminous food products having reduced amounts of legumes yet having
~5 enhanced texture and consistency. In important embodiments, the
compositions include a modified food starch component for increasing the
viscosity of the compositions and enhancing the stability of the cooked food
product. The compositions are prepared by a process that includes blending
a starch component as a slurry with legumes and water, such that the
2o composition includes a reduced amount of legumes and an amount of a
starch component effective for enhancing the viscosity of the composition, as
well as the viscosity of the cooked product, cooking the composition and
containerizing the cooked composition.
The refried bean product of this invention has a consistent "spoonable"
25 viscosity which does not vary significantly from batch to batch. Moreover,
by
varying the starch and/or bean content, the viscosity can be adjusted as
desired. The water-holding ability of the starch component improves the shelf
stability of the cooked food product which maintains a blended composition
for extended periods without separation of water from the legume mass. The
3o water of the starch component also enhances reheating of the cooked
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CA 02385148 2002-05-07
product as the starch component will release water upon application of a heat
source. The released water prevents scorching of the solid mass of the
legume product, so that the product may be more evenly reheated to a
desired temperature for consumption.
In important embodiments, the starch component is a food starch such
as dent corn starch, waxy corn starch, potato starch, waxy potato starch, rice
starch, sago starch, sorghum starch, waxy sorghum starch, tapioca starch,
and wheat starch. Preferably, the starch component has been modified, such
as by chemical treatment, so that the starch component is capable of
withstanding the physical and chemical conditions associated with preparation
of the cooked food product. Preferably, the composition includes no more
than about 10 percent of the starch component.
In other important embodiments, the legumes are beans from plants of
the Phaseolus genus, including navy, great northern, pinto, red, pink, black,
~5 and kidney beans, peas from plants of the Pisum genus, and chickpeas (i.e.,
garbanzo beans). In more preferred embodiments, the legumes are pinto
beans. In additional preferred embodiments, the composition includes no
more than about 25 percent beans, and more preferably about 19 to 22
percent beans.
2o The invention also provides methods of preparing a cooked
leguminous food product from a composition that includes a reduced legume
content. The method includes, in the process of making the food product,
adding water to legumes to provide a composition having a reduced amount
of legumes and a starch component to provide a predetermined viscosity of
25 the composition, cooking the composition, and containerizing the cooked
composition by subsequent mechanical processing of the composition which
is facilitated by the viscosity of the composition.
In one embodiment, the present invention provides a composition for a
cooked leguminous food product comprising: (1 ) legumes; (2) water in an ,
3o amount effective for providing a predetermined content of legumes in the
composition; and (3) a starch component in an amount effective for providing
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a first predetermined viscosity of the composition during preparation of the
food product for facilitating mechanical processing of the composition and for
providing a second predetermined viscosity of the food product, wherein the
food product remains stable while containerized, has a thickened consistency,
and is readily spoonable.
In another embodiment, the present invention provides a cooked bean
composition having a reduced bean content for making a cooked bean
product, the composition comprising: (1) beans; (2) water in an amount
effective for providing the bean composition having no more than about 25
percent beans; and (3) a starch component in an amount effective for
providing a first predetermined viscosity of the bean composition such that
the
composition is readily pumpable and a second predetermined viscosity of the
cooked bean product such that the cooked bean product with a reduced bean
content has enhanced texture and consistency.
~5 In still another embodiment, the present invention provides a method of
preparing a bean food product comprising: (1 ) providing an amount of beans;
(2) blending water and a starch component with the beans to provide a
mixture including a predetermined bean content; (3) heating the mixture to a
temperature and for a time to provide a predetermined processing viscosity of
2o the mixture effective for facilitating mechanical pumping and processing of
the
mixture; and (4) processing the mixture to provide a cooked bean food
product having a predetermined final viscosity effective for enhancing the
texture and consistency of the cooked bean product having a reduced bean
content.
BRIEF DESCRIPTION OF THE DRAWING
Figure 1 provides a flow diagram illustrating a preferred process for the
production of leguminous products having enhanced consistency and texture
in accordance with the present invention.
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CA 02385148 2002-05-07
DETAILED DESCRIPTION OF THE INVENTION
The invention relates to leguminous compositions that are amenable to
mechanical processing during preparation of a cooked food product having
excellent organoleptic qualities. The leguminous compositions include a
reduced amount of solids but exhibit a thick, chunky texture and a
consistency that is neither too watery nor too paste-like or gelatinous. A
reduced amount of solids in the composition without a corresponding negative
impact on the consistency of the product is possible with incorporation of a
starch component in the composition during processing. The cooked food
products made from the compositions of the invention are shelf stable for
extended periods of time and, upon reheating, have the appearance, texture
and flavor of a similar product that has been freshly prepared from scratch.
The compositions and methods of the present invention may be used in the
process of making a cooked food product from any leguminous material and
~ 5 are particularly suited for preparation of cooked bean foods, especially
canned refried beans.
As used herein, "leguminous" relates to plants that produce edible
seeds, such as beans and peas. As used herein, "legume" is intended to
include the seeds from any such leguminous plants. The terms relate to, but
2o are not limited to, beans from plants of the Phaseolus genus, including
navy,
great northern, pinto, red, pink, black, and kidney beans, peas from plants of
the Pisum genus, and chickpeas (i.e., garbanzo beans). Without wishing to
limit the scope of this invention, the present invention is described herein
for
convenience with reference to a Mexican-style refried bean product, typically
25 made with pinto beans, and a process of making such a refried bean product.
As those skilled in the art will realize, other leguminous products can be
prepared using similar techniques and processes.
Uncooked beans that will be used in the composition are sorted using
conventional methods known to those skilled in the art to remove rocks and
30 other foreign materials and then washed to remove any remaining dirt and
other debris. Whole beans" bean splits, and mixtures thereof are used in the
CA 02385148 2002-05-07
compositions of the present invention. Generally, bean mixtures containing
mainly split beans are preferred. For a refried bean composition, the ratio of
whole beans to beans splits preferably is between about 1:20 to about 1:30.
With dried beans, the beans preferably are pre-cooked or hydrated
prior to cooking to reduce the time required to cook the beans. The washed
beans are conveyed to a first tank for pre-cooking. Whole beans, bean splits,
water, and flavorants are blended in the tank to provide a bean mixture. The
amount of water used is sufficient for suspending and hydrating the beans.
Flavorants include, for example, fatty substances (e.g., fat or oil), salt,
other
spices, vegetable pieces or particulates (e.g., onion, garlic), and the like.
A
preferred apparatus is a jacketed vat, such as a 500 gallon tank, with means
for agitating, either manually or mechanically, the contents during cooking.
The bean mixture is brought to a boil and cooked until the beans are
hydrated and softened. Preferably, the bean mixture is heated at a
~5 temperature of between about 190 to about 210°F for between about
1.5 to
about 2 hours. During cooking, the bean mixture preferably is agitated at
least periodically to prevent the beans from settling and burning.
The bean mixture of the first tank is pumped to a second tank for
additional processing. In the second tank, the remaining components of the
2o refried bean product are blended with the bean mixture to form a
composition
having a reduced amount of bean solids. Additional water is added to the
composition as needed to adjust the amount of water in the composition.
Flavorants and other ingredients, including salt, other spices, oils, and/or
fats,
are added to the refried bean composition in the second tank to enhance and
25 vary the flavor of the refried bean product.
To limit the corresponding decrease in viscosity associated with a
reduction in the relative of amount of bean solids, either by increasing the
amount of water or by decreasing the amount of bean solids, the refried bean
composition of the present invention includes a starch component. The
3o amount of starch component blended with the bean composition is effective
for maintaining an in-process hot viscosity of the composition that will
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CA 02385148 2002-05-07
facilitate pumping of the composition. Preferably the amount of starch is
sufficient to achieve a Bostwick consistometer (CSC Scientific, Fairfax, VA)
reading of about 10 cm or greater at about 180°F after a period of
about 1 to
about 3 minutes. The amount of starch component also is effective for
providing a cooked bean product that has a texture, consistency, and
appearance similar to a related product freshly made from scratch with a
higher bean solids content. The starch component preferably is treated to
enhance the stability of the starch during processing of the refried bean
composition, particularly to withstand physical and chemical conditions, such
as elevated temperatures associated with cooking and physical agitation.
As used herein, "starch component" is intended to include any food
starch or starch derivative of a food starch that will act as a processing aid
during preparation of a bean composition, as well as provide stability to the
final product. Types of food starches include dent corn starch, waxy corn
starch, potato starch, waxy potato starch, rice starch, sago starch, sorghum
starch, waxy sorghum starch, tapioca starch, and wheat starch. As used
herein, "starch derivative" relates to any food starch that has been treated,
chemically or otherwise, to provide a modified food starch that will withstand
chemical and physical conditions that otherwise would be expected to cause
2o breakdown or gelation in an unmodified starch. Typical chemical treatments
for preparing modified starches include cross-linking, stabilization
(including
hydroxypropylation), pre-gelatinization, bleaching, mild acid treatment,
oxidation, and substitution. As an example, the starch component may be a
dual modified waxy maize starch such as Thermtex which is available from
25 National Starch and Chemical Company, Bridgewater, New Jersey; this cross-
linked starch provides heat and shear stability as well as shelf life
stability
against retrogradation.
In the second tank, a pre-mixed starch slurry is blended with the hot
bean mixture. Prior to introduction into the second tank, the starch slurry is
3o prepared in a separate mixer at ambient temperature. An amount of starch
component is blended with an amount of water sufficient to form a slurry.
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CA 02385148 2002-05-07
c.~enerally about 10 to about 50 percent starch in water is satisfactory; more
preferably, the about 15 to 25 percent starch in water is employed. A desired
hot viscosity of the refried bean composition after cooking in the second tank
can be achieved by adjusting the amount of starch slurry used (e.g., the hot
s viscosity can be increased by increasing the amount of slurry added).
Preferably, the starch slurryr is added to provide no more than about 10
percent starch component in the refried bean composition. Even more
preferably, the starch slurry is added to provide about 0.5 to about 2 percent
starch in the final product. Of course, the concentration of the starch slurry
and amount of starch slurry added will depend on the desired water and
starch contents fo the final product.
Prior to cooking in the second tank, the refried bean composition
includes hydrated beans (whole beans and bean splits), water, starch
component, and other ingredients, primarily for flavoring, including salt,
spices, and oil/fat component. Preferably, the bean composition includes
bean solids in an amount of no more than about 27 percent. More preferably,
the refried bean composition includes bean solids in an amount of from about
18 to about 25 percent and even more preferably from about 19 to about 21
percent. Similarly, the refried bean composition includes at least about 70
2o percent water. More preferably, the refried bean composition includes water
in an amount of from aboufi 70 to about 80 percent and even more preferably
from about 74 to about 78 percent. The refried bean composition also
includes between about 0.2 to about 10 percent starch component, more
preferably about 0.5 to about 2 percent starch component, and most
25 preferably about 0.8 to about 1.5 percent starch component. Additionally,
the
remainder of the refried bean composition includes other ingredients,
including salt, other spices, oil, fat, and/or other flavorants. Suitable oils
and
fats used in the present invention include, for example, animal fats (e.g.,
lard,
tallow, and the like) and vegetable fats (e.g., soybean, cottonseed, canola,
so and the like).
CA 02385148 2002-05-07
The refried bean cornposition is cooked in the second tank at a second
temperature for a time sufficient to yield a cooked refried bean product.
Preferably, the refried bean composition is heated to about 185 to about
195°F for about 45 to about 60 minutes. A preferred second tank is a
500
s gallon tank equipped with a mixing mechanism for blending and mechanically
agitating the refried bean composition during cooking.
The cooked refried bean composition is pumped to a holding blender
where it is held for about 10 to 15 minutes with blending at a temperature of
about 180 to about 185°F. The cooked refried bean composition is pumped
1o to down-line equipment for containerizing the composition for subsequent
shipment and sale. The refried bean composition is containerized in cans or
other suitable containers using any conventional filling and retorting methods
and equipment known to those of skill in the art. Due in part to the reduction
in solids in the cooked refried bean composition, subsequent processing of
15 the composition after cooking in the second tank is facilitated. The lower-
viscosity composition is more readily pumped through processing lines,
resulting in reduced wear on the pumps. Metering of the refried bean
composition also is enhanced.
The processed composition yields a anal, cooked refried bean product
2o having a reduced amount of bean solids with enhanced flavor, texture and
appearance. The cooked refried bean product is consumable direct from the
can or with reheating to a desired temperature.
The refried bean product of the present invention is expected to exhibit
several benefits. The starch component of the composition limits excessive
25 gelling and thickening of the product. Thus, although the refried bean
product
solidifies to some degree upon cooling, it does not solidify to such an extent
that it forms essentially a solid or extremely viscous mass in the can.
Instead,
the cooled refried bean product has a thickened consistency but is readily
spoonable from the can. Moreover, the cooled refried bean product has a
3o consistent viscosity which does not significantly change with storage time.
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The starch component also generally has the capacity to hold water.
The starch component thus enhances the stability of the canned refried bean
product by reducing water migration that otherwise would be expected to
occur in a refried bean product over time. As a result, only a minimal water
s layer or essentially no water layer will form above the product of the
present
invention as it remains stored in a can over a period of about 18 months.
Thus, the refried bean product of this invention has a shelf life of at least
about 18 months.
The cooked refried bean product also is capable of being more evenly
1o reheated to a desired temperature without scorching, particularly when
reheated over a burner. When the refried bean product is removed from the
can and reheated for consumption, the starch will yield its water content
during reheating. The presence of additional water helps to prevent
scorching of the bean solids in the thickened refried bean product. With a
15 reduced potential for scorching, the refried bean product may heated for
longer periods so as to achieve a desired temperature evenly throughout the
product. Moreover, the likelihood of "splattering" during reheated is
significantly reduced.
The present invention allows the preparation of a cooked refried bean
2o product having excellent characteristics by incorporation of a modified
food
starch during the process of making the cooked refried bean product. As
shown in~Fig. 1, the cooked refried bean product is prepared using a
procedure that includes the following: (i) providing an amount of beans 10 and
sorting and washing 12 the beans with water to remove foreign material and
25 other contaminants; (ii) suspending a mixture of whole beans and bean
splits
in water 14 and heating 16 the mixture to a temperature of about 190 to about
210°F for about 1.5 to about 2 hours to hydrate the bean mixture; (iii)
adding
a starch slurry and other desired flavor- and texture-enhancing ingredients 18
to the heated bean mixture and heating 20 the composition to a temperature
30 of about 185 to about 195°F with mixing for about 45 to about 60
minutes; (iv)
holding the cooked product with blending 22 for about 10 to about 15
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minutes; (v) filling 24 the cooked product into containers; and (vi) retorting
26
the canned product. The starch and other ingredients 18 can be added to the
cooker 20 before or during the cooking operation. Preferably, starch and
other ingredients 18 are be added to the cooker 20 during the cooking
operation. For example, the beans can be cooked for about two hours before
the starch and other ingredients 18 are added, with cooking continued for
about an additional 10 to 20 minutes after the addition. Addition of the
starch
in this manner allows it to fully cook while avoiding heat and/or shear
damage.
EXAMPLES
1o The following examples are intended to illustrate the invention and not
limit or otherwise restrict the invention. Unless otherwise noted, all
percentages and ratios in this specification are by weight.
Example 1. This example illustrates a typical composition (i.e., control)
for preparing a refried bean product having a conventional amount of bean
solids. The types and relative amounts of ingredients included in such a
conventional composition are set forth in Table 1.
TABLE 1
Ingredient Amount (%) --1
Water 70.7
2o Pinto E3eans 27.5
Salt 1.1
S ices 0.7
Example 2. This example illustrates a first composition for preparing a
refried bean product having a reduced amount of bean solids in accordance
with the present invention. The types and relative amounts of ingredients
included in the composition are set forth in Table 2
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TABLE 2
In redient Amount /o
Water 75.6
Pinto Beans (split)21.0
Pinto Beans (whole)0.6
Starch Component 1.0
Salt 1.1
S ices 0.7
Example 3. This example illustrates a second composition for
1o preparing a refried bean product having a reduced amount of bean solids in
accordance with the present invention. The types and relative amounts of
ingredients included in the composition are set forth in Table 3.
TABLE 3
In redient Arr~ou~t ~
Water 76.6
Pinto Beans (split)20.0
Pinto Beans (whole)0.6
Starch Component 1.0
Salt 1.1
2o Oil 0.6
Flavorants 0.03
Example 4. This example illustrates the effect of addition of starch
component to the composition on the hot viscosity of the cooked product.
The composition of Example 1 above was used as a control sample. The
composition of Example 2 was tested with varying amounts of starch
component added. The viscosity of cooked refried bean product was
measured using a Rapid Visco Analyzer (Newport Scientific, New South
Wales, Australia; viscosity reported in RVU units) at about 120°F.
Sample
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CA 02385148 2002-05-07
size was about 30 grams of cooked product which was stirred at about 100
rpm. The temperature of the product was about 185°F. With the reduced
bean solids composition, as the amount of starch component added to the
composition increased, the hot viscosity (120°F) of the composition
increased. A comparison of hot viscosities of compositions with differing
amounts of starch addition is set forth in Table 4. As shown in Table 4, the
hot viscosity of the control sample was considerably higher than that of the
reduced bean solids composition at lower levels of starch component
addition.
TABLE 4
Amount of Starch-Bean Solid Viscosi#y (RYU~
Com onent '/o= Content
0 (control) 28 1711
0.8 22 1234
1.0 22 1452
1.25 22 2207
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